Mobile creel

ABSTRACT

A mobile creel for organizing yarn packages and directing yarn is disclosed. In one aspect, the mobile creel has a plurality of support frames and an upright creel docking post. The front portion of the base of each support frame can be configured for engagement with the lower portion of the upright creel docking post. The creel docking post can simultaneously engage one, two, three, or four support frames.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to U.S. ProvisionalPatent Application Ser. No. 61/265,607, filed on Dec. 1, 2009, theentire disclosure of which is incorporated by reference herein for allpurposes.

FIELD OF THE INVENTION

This invention relates to a creel for holding yarn packages in a carpetmanufacturing process. More specifically, this invention relates to ahighly mobile creel configured for layered storage of yarn packagesaround a creel docking post in a carpet manufacturing process.

BACKGROUND OF THE INVENTION

A standard creel has a frame provided with a plurality of vertical rowsof holders each adapted to hold a respective bobbin comprised of atubular core and a mass of filament—yarn or thread—wound on the core. Afilament is pulled from each bobbin and guided through a respective eye,whence it passes to a warp or weft system of a loom or the like. Astandard creel can hold hundreds and even thousands of bobbins, thusspace requirement is a problem. Additionally, conventional creel designrequires that the tufting machine be placed out of operation during thetimes an operator is required to change the bobbins on the creel inorder to change yarns. Further, a significant amount of labor isrequired to successfully relocate a standard creel or to load or unloadyarn packages on the creel.

Thus, there is a need in the pertinent art for an easily movable creelhaving a compact design for securely holding yarn packages.Additionally, there is a need in the pertinent art for a creel that isconfigured to allow for efficient loading and unloading of yarnpackages.

SUMMARY

The invention relates to a mobile creel for organizing yarn packages anddirecting yarn to a carpet manufacturing process. A mobile creelprovides flexibility for carpet manufactures in that operators canpre-load mobile creels with yarn packages and roll the mobile creels toa desired location, where the mobile creel can be tied into an existingyarn feed. Due to the mobility of the mobile creel, heavier and largercreel packages can be used so as to extend the runtime between creelingsthroughout the carpet manufacturing process. Because of these extendedruntimes and the decreased need for loading and unloading of creelpackages, material-handling labor within a textile plant issignificantly reduced.

In one aspect, the mobile creel has at least one support frame and anupright creel docking post. Each support frame of the mobile creel has abase with a front portion and a rear portion. The base of each supportframe can have a substantially triangular shape. In another aspect, eachsupport frame has a plurality of substantially upright support membersextending upwardly from the rear portion of the base. In a furtheraspect, each support frame can have a plurality of spaced creel mountspositioned on at least one of the support members. Each creel mount canbe configured to selectively hold a yarn package.

In another aspect, the upright creel docking post has a lower portionand an upper portion. The front portion of the base of each supportframe can be configured for engagement with the lower portion of theupright creel docking post. In a further aspect, each creel mount can beconfigured so as to be operably positioned to substantially face aportion of the upright creel docking post after engagement of the baseby the upright creel docking post. In one non-limiting example, thecreel docking post can simultaneously engage one, two, three, or foursupport frames.

In an additional aspect, the support frame can have a plurality ofcasters to enable the mobile creel to be readily moved over flooringsurfaces within a carpet manufacturing plant. In a further aspect, thecreel mounts can be evenly spaced along the outer support members tocreate a plurality of levels for securing yarn packages. In anotheraspect, the support frame can have a plurality of substantiallyhorizontal creel package separators mounted on the support members.

In a further aspect, the lower portion of the upright creel docking postcan have a guide plate configured to receive the base of each supportframe. In another aspect, the lower portion of the docking post has atleast one magnet for maintaining the engagement of the front portion ofeach base with the lower portion of the docking post. In still anotheraspect, the upper portion of the upright creel docking post can havemeans for directing at least one path of yarn from the support frames toa selected process, including, for example and without limitation, acarpet tufting machine or a heat setting. For example and withoutlimitation, the means for directing at least one path of yarn can be,alone or in combination, a series of spaced pre-guide rings, a series ofspaced ball tension controllers, a plurality of yarn guides, or thelike.

DETAILED DESCRIPTION OF THE FIGURES

These and other features of the preferred embodiments of the inventionwill become more apparent in the detailed description in which referenceis made to the appended drawings wherein:

FIG. 1 is a perspective view of the support frame of the mobile creelaccording to one aspect of the present invention.

FIG. 2 is a perspective view of the upright creel docking post of themobile creel according to one aspect of the present invention.

FIG. 3 is a perspective view of the mobile creel according to one aspectof the present invention, illustrating the docking of two support framesto the upright creel docking post.

FIG. 4 is a perspective view of the mobile creel according to one aspectof the present invention, illustrating the docking of two support framesto the upright creel docking post in a “magazine creeling”configuration.

FIG. 5 is an elevational view of the mobile creel according to oneaspect of the present invention, illustrating the docking of foursupport frames to the upright creel docking post such that the spacedcreel mounts of the support frames are operably positioned to extendalong a mount axis.

DETAILED DESCRIPTION OF THE INVENTION

The present invention can be understood more readily by reference to thefollowing detailed description, examples, drawing, and claims, and theirprevious and following description. However, before the present devices,systems, and/or methods are disclosed and described, it is to beunderstood that this invention is not limited to the specific devices,systems, and/or methods disclosed unless otherwise specified, as suchcan, of course, vary. It is also to be understood that the terminologyused herein is for the purpose of describing particular aspects only andis not intended to be limiting.

The following description of the invention is provided as an enablingteaching of the invention in its best, currently known embodiment. Tothis end, those skilled in the relevant art will recognize andappreciate that many changes can be made to the various aspects of theinvention described herein, while still obtaining the beneficial resultsof the present invention. It will also be apparent that some of thedesired benefits of the present invention can be obtained by selectingsome of the features of the present invention without utilizing otherfeatures. Accordingly, those who work in the art will recognize thatmany modifications and adaptations to the present invention are possibleand can even be desirable in certain circumstances and are a part of thepresent invention. Thus, the following description is provided asillustrative of the principles of the present invention and not inlimitation thereof.

As used throughout, the singular forms “a,” “an” and “the” includeplural referents unless the context clearly dictates otherwise. Thus,for example, reference to “a yarn package” can include two or more suchyarn packages unless the context indicates otherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance may or may not occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

In one embodiment, the invention relates to a mobile creel 10 fororganizing yarn packages 20 and directing yarn to a carpet manufacturingprocess. The mobile creel 10 provides flexibility for carpetmanufactures in that operators can pre-load portable creels with yarnpackages 20 for future runs and move them into position when needed. Inone aspect, the mobile creel 10 comprises at least one support frame 100and an upright creel docking post 200.

In one aspect, and referring to FIG. 1, each support frame 100 of themobile creel comprises a base 110 having a front portion and a rearportion. In this aspect, the base 110 of each support frame 100 can havea substantially triangular shape. In another aspect, each support frame100 comprises a plurality of substantially upright support members 130extending upwardly from the rear portion of the base 110. In a furtheraspect, each support frame 100 comprises a plurality of spaced creelmounts 150 positioned on at least one of the support members 130. As onewill appreciate, each spaced creel mount 150 can be secured to itsrespective support member 130 by any means known in the art, including,for example and without limitation, welding of the creel mounts 150 totwo sides of their respective support members 130. In this aspect, eachcreel mount 150 can be configured to selectively hold a yarn package 20.It is contemplated that, in one aspect, the creel mount can comprise aconventional creel mount. For example and without limitation, each creelmount 150 can comprise a tempered bent-wire package holder.

In one aspect, and referring to FIG. 2, the upright creel docking post200 comprises a lower portion and an upper portion. In another aspect,and referring to FIGS. 3 and 4, the front portion of the base 110 can beconfigured for engagement with the lower portion of the upright creeldocking post 200. In a further aspect, each creel mount 150 can beconfigured so as to be oriented toward a portion of the upright creeldocking post 200 after operative engagement of the base 110 by theupright creel docking post. In still a further aspect, each creel mount150 can be configured so as to be operably positioned to substantiallyface a portion of the upright creel docking post 200 after operativeengagement of the base 110 by the upright creel docking post.

In another aspect, and referring to FIG. 1, the plurality ofsubstantially upright support members 130 comprises two outer supportmembers. In this aspect, the plurality of spaced creel mounts 150 can bemounted on the two outer support members. Optionally, the uprightsupport members 130 can also comprise a central support member. In anadditional aspect, the support frame 100 comprises a central gusset 140attached to the central support member and the base 110.

In an additional aspect, and referring to FIG. 1, the support frame 100comprises a transport means, such as, for example and withoutlimitation, casters, rollers, skids, or the like, for allowing movementof the support frame relative to the upright creel docking post 200. Inone aspect, and without limitation, a plurality of casters 120 can bemounted on a bottom surface of the base. In this aspect, the pluralityof casters can comprise at least one lockable caster mounted underneaththe rear portion of the base 110, as well as a center pivoting castermounted underneath the top portion of the base. As one skilled in theart will appreciate, the casters 120 enable the mobile creel to rollalong flooring surfaces within a carpet manufacturing plant and theplurality of substantially upright support members 130, coupled with theplurality of casters 120, allows for easy steering of the mobile creelduring transfers from one process to another.

In a further aspect, and referring to FIG. 1, the creel mounts 150 canbe evenly spaced along the outer support members to create a pluralityof spaced levels 170 for securing yarn packages 20. In one aspect, it iscontemplated that each level 170 would be substantially horizontal,i.e., transverse to the longitudinal axis of the respective outersupport members. For example, eight spaced creel mounts 150 can bepositioned on the two outer support members such that there are fourlevels for securing yarn packages 20, with each level 170 having twospaced creel mounts.

In another aspect, the support frame 100 can comprises a plurality ofsubstantially horizontal creel package separators 160 mounted on thesupport members 130. It is contemplated that the creel packageseparators 160 can be configured to divide the levels 170 for securingyarn packages 20. As one will appreciate, the creel package separators160 help prevent entanglement of yarn packages 20 located on differentlevels 170 of the mobile creel.

As illustrated in FIG. 2, in one aspect, the lower portion of theupright creel docking post 200 comprises a guide plate 210 configured toreceive the base 110 of each support frame 100. In this aspect, theguide plate can have a plurality of slots defined therein that areconfigured to receive the front portion of each base 110. In anotheraspect, the lower portion of the docking post 200 can comprise at leastone magnet. It is contemplated that the at least one magnet can beconfigured to maintain the engagement of the front portion of each base110 with the lower portion of the docking post 200. In an additionalaspect, the front portion of each base can also comprise at least onemagnet that is configured to attract either a portion of a slot in theguide plate or to be attracted to a magnet positioned on the lowerportion of the docking post. It is contemplated that the additionalmagnets of the docking post can reinforce the engagement of the frontportion of each base 110 with the docking post. Optionally, the guideplate 210 or the front portion of the base can comprises a rubber bumperfor dampening the impact of the engagement of the support frame 100 bythe docking post 200.

In another aspect, and referring to FIG. 2, the upper portion of theupright creel docking post 200 can comprise means for directing at leastone path of yarn 30 from the at least one support frame 100 to aselected process, including, for example and without limitation, acarpet tufting machine, a heat setting device and the like. In oneaspect, the means for directing at least one path of yarn comprises aseries of spaced pre-guide rings 230 that can be positioned along thelongitudinal length of the upper portion of the docking post 200. It iscontemplated that the pre-guide rings 230 can be configured to receiveat least one path of yarn 30 from the at least one support frame 100. Asone will appreciate, the pre-guide rings 230 can maintain even tensionin the path of yarn 30 so that off-winding yarn harmonics are reduced.

In an additional aspect, the means for directing at least one path ofyarn can further comprises a series of spaced ball tension controllers250 positioned along the longitudinal length of the upper portion of thedocking post 200. In one exemplary aspect, the series of spacedpre-guide rings 230 and the series of spaced ball tension controllers250 can be positioned in an interdigitated relationship. As one willappreciate, the spaced ball tension controllers 250 can be configured tocreate even tension in the yarn 30 used during carpet manufacturingprocesses. Known ball tension devices, such as, for example and withoutlimitation, Otto Zollinger (OZ®) ball tension devices, can be used forthis purpose. In a further aspect, the means for directing at least onepath of yarn comprises a plurality of yarn guides 270 mounted to theupper portion of the docking post 200. In this aspect, the yarn guides270 can be configured to guide at least one path of yarn into apredetermined yarn formation. Optionally, the yarn guides 270 can belocking yarn guides, such as, for example and without limitation, Yuasalocking yarn guides.

In still another aspect, and referring to FIGS. 3, 4, and 5, the frontportion of the base 110 of each support frame 100 can be engaged withthe lower portion of the upright creel docking post 200. For example,and without limitation, the mobile creel can have one, two, three, orfour support frames in engagement with the docking post 200. Asillustrated in FIGS. 4 and 5, it is contemplated that, following theengagement of a support frame 100 with the creel docking post 200, theoff-winding yarn end of one yarn package 20 can be tied to the tail ofan adjacent yarn package on the same level of the support frame to allowfor “magazine creeling,” which creates a continuous path of yarn usingmultiple yarn packages. It is further contemplated that “magazinecreeling” can be expanded by linking yarn packages 20 from adjacentsupport frames 100 that share a common pre-guide ring 230.

In another embodiment, and referring to FIGS. 3 and 4, the inventionrelates to a support frame 100 for engagement with an upright dockingpost 200 of a mobile creel 10 organizing yarn packages 20 and directingyarn to a carpet manufacturing process. In one aspect, the support frame100 comprises a substantially triangular base 110 having a front portionand a rear portion. In one aspect, the front portion comprises a vertexof the substantially triangular base 110. In this aspect, the frontportion of the base 110 can be configured for engagement with thedocking post 200. Additionally, in another aspect, the support frame 100comprises a plurality of substantially upright support members 130extending upwardly from the rear portion of the base 110. In stillanother aspect, the support frame 100 comprises a plurality of spacedcreel mounts 150 positioned on at least one support member 130 of theplurality of support members. In this aspect, each creel mount 150 canbe configured to selectively hold a yarn package 20. Further, each creelmount 150 can be operably positioned to extend along a mount axis. Asillustrated in FIG. 4, it is contemplated that the mount axis A of eachrespective creel mount 150 can substantially bisect the vertex of thefront portion of the substantially triangular base 110.

In use, and referring to FIGS. 3, 4, and 5, the mobile creel 10 can beprovided to organize yarn packages 20 and direct yarn to a carpetmanufacturing process. A yarn package 20 can be secured on at least onespaced creel mount 150 of the plurality of spaced creel mounts. Thefront portion of the base 110 of at least one selected support frame 100can be positioned so as to engage the lower portion of the upright creeldocking post 200. Further, the yarn of at least one yarn package 20secured on the at least one selected support frame 100 can be positionedin communication with the means for directing at least one path of yarnfrom the at least one support frame 100 to a selected process.

Optionally, and referring to FIGS. 3, 4, and 5, the plurality of spacedcreel mounts 150 can be evenly spaced along at least two support members130 of the plurality of substantially upright support members to createa plurality of levels 170 for securing yarn packages 20. In one aspect,the step of securing a yarn package 20 on at least one creel mount 150further comprises securing at least two yarn packages on respectivecreel mounts within a selected level for securing yarn packages. In afurther aspect, the step of positioning the yarn of at least one yarnpackage 20 further comprises tying yarn from a first yarn packagesecured to a first spaced creel mount within the selected level to yarnfrom a second yarn package secured to a second spaced creel mount withinthe selected level.

Although several embodiments of the invention have been disclosed in theforegoing specification, it is understood by those skilled in the artthat many modifications and other embodiments of the invention will cometo mind to which the invention pertains, having the benefit of theteaching presented in the foregoing description and associated drawings.It is thus understood that the invention is not limited to the specificembodiments disclosed hereinabove, and that many modifications and otherembodiments are intended to be included within the scope of the appendedclaims. Moreover, although specific terms are employed herein, as wellas in the claims which follow, they are used only in a generic anddescriptive sense, and not for the purposes of limiting the describedinvention, nor the claims which follow.

1. A mobile creel for organizing yarn packages and directing yarn, the mobile creel comprising: an upright creel docking post having a lower portion and an upper portion; and at least one support frame, each support frame comprising: a base having a front portion and a rear portion; a plurality of substantially upright support members extending upwardly therefrom the rear portion of the base; and a plurality of spaced creel mounts positioned thereon at least one support member of the plurality of substantially upright support members, each creel mount configured to selectively hold a yarn package, wherein the front portion of the base of each support frame is configured for engagement with the lower portion of the upright creel docking post, and wherein each creel mount of the plurality of spaced creel mounts is oriented toward the upright creel docking post.
 2. The mobile creel of claim 1, wherein the base of each support frame has a substantially triangular shape.
 3. The mobile creel of claim 1, wherein each spaced creel mount of the plurality of spaced creel mounts comprises a tempered bent-wire package holder.
 4. The mobile creel of claim 1, wherein the plurality of substantially upright support members comprises two outer support members and a central support member, and wherein the plurality of spaced creel mounts are positioned thereon the two outer support members.
 5. The mobile creel of claim 4, wherein each support frame of the at least one support frame further comprises means for allowing the support frame to be moved relative to the upright creel docking post.
 6. The mobile creel of claim 4, wherein the means for allowing the support frame to be moved comprises a plurality of casters coupled to a bottom surface of the base.
 7. The mobile creel of claim 6, wherein the plurality of casters comprises: at least one lockable caster mounted underneath the rear portion of the base; and a center pivoting caster mounted underneath the front portion of the base.
 8. The mobile creel of claim 4, wherein the plurality of spaced creel mounts are substantially evenly spaced along the longitudinal length of the outer support members to create a plurality of levels for securing yarn packages, and wherein adjacent creel mounts on the respective outer support members are substantially co-planar.
 9. The mobile creel of claim 8, wherein each support frame of the at least one support frame further comprises a plurality of substantially horizontal creel package separators mounted thereon the plurality of substantially upright support members to divide the levels for securing yarn packages.
 10. The mobile creel of claim 1, wherein the lower portion of the upright creel docking post comprises a guide plate having a plurality of slots configured to receive the front portion of the base of each support frame.
 11. The mobile creel of claim 1, wherein the lower portion of the upright creel docking post comprises at least one magnet, and wherein the at least one magnet is configured to maintain the engagement of the front portion of the base of each support frame with the lower portion of the upright creel docking post.
 12. The mobile creel of claim 1, wherein the upper portion of the upright creel docking post comprises means for directing at least one path of yarn therefrom the at least one support frame.
 13. The mobile creel of claim 12, wherein the means for directing at least one path of yarn therefrom the at least one support frame comprises a series of spaced pre-guide rings positioned along the upper portion of the upright creel docking post.
 14. The mobile creel of claim 13, wherein the means for directing at least one path of yarn therefrom the at least one support frame further comprises a series of spaced ball tension controllers positioned along the upper portion of the upright creel docking post, and wherein the series of spaced pre-guide rings and the series of spaced ball tension controllers are positioned in an interdigitated relationship.
 15. The mobile creel of claim 14, wherein the means for directing at least one path of yarn therefrom the at least one support frame further comprises a plurality of yarn guides mounted thereto the upper portion of the upright creel docking post, wherein each yarn guide of the plurality of yarn guides is configured to guide the at least one path of yarn into a predetermined yarn formation.
 16. The mobile creel of claim 1, wherein the front portion of the base of each support frame of the at least one support frame is engaged with the lower portion of the upright creel docking post.
 17. The mobile creel of claim 16, wherein the at least one support frame comprises a plurality of support frames.
 18. The mobile creel of claim 17, wherein the plurality of support frames is selected from a group consisting of two, three, and four support frames.
 19. The mobile creel of claim 1, wherein each creel mount of the plurality of spaced creel mounts is operably positioned to substantially face the upright creel docking post.
 20. A support frame for engagement with an upright docking post of a mobile creel for organizing yarn packages and directing yarn, the support frame comprising: a substantially triangular base having a vertex and a rear portion; a plurality of substantially upright support members extending upwardly therefrom the rear portion of the substantially triangular base; and a plurality of spaced creel mounts positioned thereon at least one support member of the plurality of substantially upright support members, each creel mount configured to selectively hold a yarn package, wherein the vertex of the base is configured for engagement with the upright creel docking post, wherein each creel mount of the plurality of spaced creel mounts is operably positioned to extend along a mount axis, wherein the mount axis of each respective spaced creel mount is oriented toward the vertex of the substantially triangular base.
 21. A method for organizing yarn packages and directing yarn, the method comprising: providing a mobile creel, the mobile creel comprising: an upright creel docking post having a lower portion and an upper portion; and a plurality of support frames, each support frame comprising: a base having a front portion and a rear portion; a plurality of substantially upright support members extending upwardly therefrom the rear portion of the base; and a plurality of spaced creel mounts positioned thereon at least one support member of the plurality of substantially upright support members, each creel mount configured to selectively hold a yarn package, wherein the front portion of the base of each support frame is configured for engagement with the lower portion of the upright creel docking post, wherein each creel mount of the plurality of spaced creel mounts is oriented toward the upright creel docking post, and wherein the upper portion of the upright creel docking post comprises means for directing at least one path of yarn therefrom the plurality of support frames; securing a yarn package thereon at least one spaced creel mount of the plurality of spaced creel mounts; positioning the front portion of the base of at least one selected support frame of the plurality of support frames in engagement with the lower portion of the upright creel docking post; and positioning the yarn of at least one yarn package secured thereon the at least one selected support frame in communication with the means for directing at least one path of yarn therefrom the plurality of support frames.
 22. The method of claim 21, wherein the plurality of spaced creel mounts are substantially evenly spaced along at least two support members of the plurality of substantially upright support members to create a plurality of levels for securing yarn packages, wherein adjacent creel mounts on the respective support members are substantially co-planar, wherein the step of securing a yarn package thereon at least one spaced creel mount further comprises securing at least two yarn packages thereon respective spaced creel mounts within a selected level of the plurality of levels for securing yarn packages, and wherein the step of positioning the yarn of at least one yarn package further comprises serially tying yarn from a first yarn package secured thereon a first spaced creel mount within the selected level to yarn from a second yarn package secured thereon a second spaced creel mount within the selected level. 